Investigation into the nature of productivity gains observed during the Airplane Game lean simulation

Abstract

Research Question: What is the nature of productivity gains observed during live playing of the lean simulation, the “airplane game”? Purpose: The purpose of this research is to investigate and identify the nature of productivity gains observed during live playing of the lean simulation, the airplane game. The intent is two-fold: (1) to identify the specific mechanistic impact of each lean principle, as it is successively introduced; and (2) to identify the productivity contributions of non-mechanistic phenomena such as learning curve and/or Hawthorne Effect. The game serves as a proxy for controlled experimentation in the field—experimentation that is difficult to conduct on actual construction projects but that is important when making claims regarding generalizability of results. Research Method: To identify the specific mechanistic impact of each lean principle, researchers used Microsoft Excel to graphically map the airplane simulation, stationby-station and second-by-second. Metrics such as time to first batch, number of successful planes and work-in-process were derived from the Excel graphic and evaluated after each round to understand the specific impact of each successivelyintroduced lean principle. To identify the specific impact of non-mechanistic processes on productivity (such as learning curve and Hawthorne effect), researchers compared average results from live playings against results derived from the Excel graphic. Findings: Comparison of results obtained from the Excel graphic demonstrate the following: (1) reducing batch sizes primarily results in reduced time to first batch; transitioning from a push to pull system primarily results in reduction of work-inprocess; and transitioning from an uneven loading of work to a work-leveled system primarily results in an increased amount of final product; and (2) the contribution of productivity gains from non-mechanistic phenomena such as learning curve and/or Hawthorne effect is relatively minor (i.e. approximately 70% of productivity gains in

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